Flocking

ABSTRACT

A flocking apparatus for applying flock fibers to an article travelling therethrough comprising an article support, a flock distributor comprising a rotary drum having peripheral apertures arranged in a predetermined pattern, mounted above the article support for rotation about an axis parallel to the article support and transverse to the path of travel of said article, and spaced from the article support by a distance greater than the thickness of said article, a flock supply arranged to supply flock to the interior of the drum, means for rotating the drum at a selected peripheral speed related to the linear speed of the article and in a direction such that the part of the drum adjacent the article is moving in the same horizontal direction as the article beneath, and means for establishing an electrostatic field between the flock distributor and the article.

United States Patent 7 Walsh 51 July 25,1972

1 1 FLOCKING David I. Walsh, Barrington, R.l.

[73] Assignee: Indev, Inc., Pawtucket, RJ.

[22] Filed: Dec. 24, 1969 [21] Appl. No.: 887,986

[72] Inventor:

2,681,446 6/1954 Ewing et al. ..117/17 3,408,986 11/1968 Walsh et al. ..118/636 Primary Examiner-Mervin Stein Assistant Examiner-Leo Millstein AltomeyW. R. Hulbert [5 7] ABSTRACT A flocking apparatus for applying flock fibers to an article travelling therethrough comprising an article support, a flock distributor comprising a rotary drum having peripheral apertures arranged in a predetermined pattern, mounted above the article support for rotation about an axis parallel to the article support and transverse to the path of travel of said article, and spaced from the article support by a distance greater than the thickness of said article, a flock supply arranged to supply flock to the interior of the drum, means for rotating the drum at a selected peripheral speed related to the linear speed of the article and in a direction such that the part of the drum adjacent the article is moving in the same horizontal direction as the article beneath, and means for establishing an electrostatic field between the flock distributor and the article.

Puma! July 25, 1912 BEST AVAMBLE COPY 3,678,894

ZSheets-Sheet 2 FLOCKING This invention relates to feeding flock in flocking apparatus.

An object of this invention is to apply flock to articles in a preselected pattern, uniformly, rapidly, easily, and efficiently.

Another object is to produce multi-patterned (e.g., multicolored or multi-textured) flocked articles without using elaborate or multiple adhesive feed assemblies.

The invention features a flocking apparatus for applying flock fibers to an article travelling therethrough comprising an article support, a flock distributor comprising a rotary drum having peripheral apertures arranged in a predetermined pattern, mounted above the article support for rotation about an axis parallel to the article support and transverse to the path of travel of said article, and spaced from the article support by a distance greater than the thickness of said article, a flock supply arranged to supply flock to the interior of the drum, means for rotating the drum at a selected peripheral speed related to the linear speed of the article and in a direction such that the part of the drum adjacent the article is moving in the same horizontal direction as the article beneath, and means for establishing an electrostatic field between the flock distributor and the article. In preferred embodiments, the flock distributor includes an axially extending stationary feed trough, having side walls, mounted within the drum adjacent the interior surface of the lowermost peripheral portion of the drum, the side walls being spaced apart adjacent the drum to provide an axially extending feed channel sized to distribute flock over a predetermined arc of said drum; flock is supplied to one end of the trough and distributed along the trough by a rotary spiral brush, and excess flock is collected at the opposite end of the trough; the flock distributor has an electrically conductive portion connected to ground potential and an electrically-conductive member located beneath the article is connected to a source of electrical potential; the drum is rotated at a peripheral speed equal to the linear speed of the article past the drum; and a plurality of such flock distributors have complementary patterns, and are arranged and driven to apply flock successively to previously unflocked portions of the article.

Other objects, features and advantages will be apparent to one skilled in the art from the following description of a preferred embodiment of the invention, taken together with the attached drawings thereof, in which:

FIG. 1 is an end view, partially broken away, of a flocking apparatus embodying the present invention;

FIG. 2 is a side view of the flocking apparatus of FIG. 1, also partially broken away;

FIG. 3 is a sectional view, with portions broken away, of the flock distributing portion of the apparatus of FIGS. 1 and 2; and

FIG. 4 is another sectional view, with portions broken away, of the flock distributing portion of FIG. 3, along section 44 thereof.

The figures show a flocking apparatus which includes a housing 12, a feed cyclone I4 which feeds flock distributor 16 through conduit 18, and article-supporting blanket 22, for supporting the article 23 to be flocked. Blanket 22 extends between entrance and exit openings 24, 26, and has its ends anchored to frames 27, 28, respectively, these frames being secured to housing 12. Flock collection hopper 30 is mounted beneath blanket 22 and is connected through conduit 33 to feed cyclone 14, whereas suction nozzle 35 is connected through conduit 36 to return cyclone 40. A first electrically conductive plate 42 is mounted beneath blanket 22, and is connected to a source of electrical potential (e.g., an AC power source, not shown). An electrically conductive grid 44 is suspended above blanket 22 on rod 46 from a support 48 which is secured to housing 12, and is connected to a source of electrical potential (e.g., an AC power source) higher than the potential of a second conductive plate 49 (which is, e.g., at ground potential).

Referringnow to FIGS. 3 and 4, flock distributor 16 includes a perforated cylindrical drum 50, having a plurality of perforations 52 arranged in a predetermined pattern dependent upon the pattern desired to be produced on the article 23 passing therebeneath, and a feed trough 54 having side walls 58 terminating closely adjacent the interior surface 55 of drum 50, defining therebetween an axially extending feed channel 59. A spiral brush 60 is mounted on rotatable shaft 61, in communication with the interior surface 55 of drum 50 through feed channel 59 to distribute flock along the entire axial extent of channel 59 from feed conduit 18 to scavenging conduit 66, which is connected to return cyclone 40. Shaft 61 is rotated at the desired peripheral speed through sprocket wheel 68, drive chain 70, sprocket wheel 72, and motor 74. Rotating drum 50 has a coaxial sprocket wheel 75 integral with one end thereof, which is rotated by drive chain 76, which is in turn driven by a sprocket wheel 77 and motor 78. Two pairs of drum supports 80, 82 are secured to housing 12, and include bearing surfaces 84 contacting the interior surface of drum 50 and thereby supporting drum S0 rotatably thereon. A portion of flock distributor 16 is connected to ground potential. This connection may be made simply by grounding housing 12, or, e.g., a ground lead may be secured to drum 50.

In operation, flock is fed from feed cyclone 14 through conduit 18 to one end of drum 50, and is distributed along channel 59 by rotating spiral brush 60. Excess flock is scavenged from the other end of drum 50 through conduit 66. Flock distributed along channel 59 will pass through a perforation 52 when that perforation is adjacent the channel 59, i.e., is at the lowermost extent of its peripheral movement. When the peripheral speed of the drum is the same as the linear speed of the article beneath and the part of the drum adjacent the article is moving in the same direction as the article beneath, the pattern of the periphery of the drum will be repeated on the surface of the article beneath, the flock being orientated by the electrostatic field provided between the flock distributor l6 and plate 42 through article 23, and also by the electrostatic field produced between grid 44, or a series of such grids (not shown), and plate 49. The article, prior to entering opening 24, is completely covered with a suitable adhesive, the flock-applying pattern leaving substantial adhesively coated areas of the article without flock. If desired, the article having a pattern produced by travel through one apparatus 10 or past one distributor 16 may thereafter be fed into another flocking apparatus or past another flock distributor, which has a drum with a pattern complementing that of drum 50, so that flock may be applied to previously unflocked portions of the article. This second flock may be identical with, or be of a varying color, texture, size (length or denier) from the first applied flock. Thus, multi-pattemed flocked articles may be produced without the necessity of having multiple patterned adhesiveapplying rollers.

Excess flock is scavenged from the article leaving the flocking apparatus by suction nozzle 35, and flock passing to hopper 26 is returned to feed cyclone 14.

Other embodiments will appear to those skilled in the art.

What is claimed is:

I. A flocking apparatus for applying flock fibers to an article travelling therethrough in a preselected pattern, said pattern including areas covered with flock and other areas not covered with flock, and said apparatus comprising:

an article support;

a flock distributor comprising a rotary drum having peripheral apertures arranged in a predetermined pattern dependent upon the areas of said preselected pattern covered with flock, mounted above said article support for rotation about an axis parallel to said article support and transverse to the path of travel of said article, said drum spaced from said article support by a distance greater than the thickness of said article;

a flock supply arranged to supply flock fibers to the interior of said drum;

means for rotating said drum at a selected peripheral speed related to the linear speed of said article past said drum, and in a direction such that the part of the drum adjacent said article support is moving in the same direction as said article beneath; and,

means for establishing an electrostatic field between said flock distributor and said article and causing flock fibers from said drum to be deposited on the portions of said article corresponding to said areas of said preselected pattern covered with flock and not on portions of said article corresponding to said other areas of said pattern.

2. A flocking apparatus according to claim 1 wherein said flock distributor includes an axially extending stationary feed trough, sized to distribute flock over a predetermined arc of said drum, and mounted within said drum adjacent the interior surface of the lowermost peripheral portion of said dmm.

3. A flocking apparatus according to claim 2 wherein said feed trough includes opposed side walls spaced from one another adjacent said drum to provide a feed channel extending axially of said drum and defining said predetermined arc of said drum.

4. A flocking apparatus according to claim 3 wherein said flock supply is arranged to supply flock to one end of said feed trough and including means for spreading flock along said trough.

5. A flocking apparatus according to claim 4 wherein said spreading means comprises a rotary spiral brush mounted within said drum and arranged to communicate with the said interior drum surface through said feed channel.

6. A flocking apparatus according to claim 5 including structure for collecting excess flock at the opposite end of said trough.

7. A flocking apparatus according to claim 1 wherein said flock distributor has an electroconductive portion connected to ground potential, and said apparatus includes an electrically conductive member located beneath said article and maintained at a higher electrical potential than said electroconductive flock distributor portion.

8. A flocking apparatus according to claim 1 wherein said drum is driven at a peripheral speed equal to the linear speed of said article past said drum, and said preselected pattern is a repeat of the pattern of said apertures.

9. In combination with the flocking apparatus of claim I,

at least one additional flock distributor in communication with a flock supply and comprising an additional rotary drum perforated in a predetermined pattern complementary to the pattern of the said rotary drum of said flocking apparatus, said additional flock distributor being mounted above an additional article support which supports said article to be flocked while the article travels past said drum for rotation about an axis parallel to said additional article support and transverse to the path of travel of said article with the lowermost peripheral portion of said additional drum spaced from said additional article support by a distance greater than the thickness of said article,

means for rotating said additional drum at a selected peripheral speed related to the linear speed of said article past said additional drum, and in a direction such that the part of said additional drum adjacent said additional article support is moving in the same horizontal direction as said article beneath, andv means for establishing an electrostatic field between said additional flock distributor and said article and causing flock fibers from said additional drum to be deposited from said additional drum onto previously unflocked portions of said article and not on previously flocked portions of said article.

10. The combination of claim 9 wherein each drum is driven at a peripheral speed equal to the linear speed of said article past said each drum.

1]. The combination of claim 10 wherein each drum is driven at a peripheral speed equal to the linear speed of said article past said drum.

12. The flocking apparatus of claim 1 wherein said flock distributor permits flock fibers to be dischar ed from said drum through respective ones of said apertures urmg the portion of UNITED STATES OFFECE CERTIFICATE OF CORRECTEON Patent No. 3.678,89 4 Dated July 25, 1972 Inventor-(s) David I Walsh It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Cancel claim 11.

Signed and sealed this 23rd day of January 1973.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attestlng Officer Commissioner of Patents FORM PO-1050 (10-69) USCOM'WDC (mint-"P69 a us GOVERNMENT wnm'rmo orncz: I989 0-366-334 

1. A flocking apparatus for applying flock fibers to an article travelling therethrough in a preselected pattern, said pattern including areas covered with flock and other areas not covered with flock, and said apparatus comprising: an article support; a flock distributor comprising a rotary drum having peripheral apertures arranged in a predetermined pattern dependent upon the areas of said preselected pattern covered with flock, mounted above said article support for rotation about an axis parallel to said article support and transverse to the path of travel of said article, said drum spaced from said article support by a distance greater than the thickness of said article; a flock supply arranged to supply flock fibers to the interior of said drum; means for rotating said drum at a selected peripheral speed related to the linear speed of said article past said drum, and in a direction such that the part of the drum adjacent said article support is moving in the same direction as said article beneath; and, means for establishing an electrostatic field between said flock distributor and said article and causing flock fibers from said drum to be deposited on the portions of said article corresponding to said areas of said preselected pattern covered with flock and not on portions of said article corresponding to said other areas of said pattern.
 2. A flocking apparatus according to claim 1 wherein said flock distributor includes an axially extending stationary feed trough, sized to distribute flock over a predetermined arc of said drum, and mounted within said drum adjacent the interior surface of the lowermost peripheral portion of said drum.
 3. A flocking apparatus according to claim 2 wherein said feed trough includes opposed side walls spaced from one another adjacent said drum to provide a feed channel extending axially of said drum and defining said predetermined arc of said drum.
 4. A flocking apparatus according to claim 3 wherein said flock supply is arranged to supply flock to one end of said feed trough and including means for spreading flock along said trough.
 5. A flocking apparatus according to claim 4 wherein said spreading means comprises a rotary spiral brush mounted within said drum and arranged to communicate with the said interior drum surface through said feed channel.
 6. A flocking apparatus according to claim 5 including structure for collecting excess flock at the opposite end of said trough.
 7. A flocking apparatus according to claim 1 wherein said flock distributor has an electroconductive portion connected to ground potential, and said apparatus includes an electrically conductive member located beneath said article and maintained at a higher electrical potential than said electroconductive flock distributor portion.
 8. A flocking apparatus according to claim 1 wherein said drum is driven at a peripheral speed equal to the linear speed of said article past said drum, and said preselect ed pattern is a repeat Of the pattern of said apertures.
 9. In combination with the flocking apparatus of claim 1, at least one additional flock distributor in communication with a flock supply and comprising an additional rotary drum perforated in a predetermined pattern complementary to the pattern of the said rotary drum of said flocking apparatus, said additional flock distributor being mounted above an additional article support which supports said article to be flocked while the article travels past said drum for rotation about an axis parallel to said additional article support and transverse to the path of travel of said article with the lowermost peripheral portion of said additional drum spaced from said additional article support by a distance greater than the thickness of said article, means for rotating said additional drum at a selected peripheral speed related to the linear speed of said article past said additional drum, and in a direction such that the part of said additional drum adjacent said additional article support is moving in the same horizontal direction as said article beneath, and means for establishing an electrostatic field between said additional flock distributor and said article and causing flock fibers from said additional drum to be deposited from said additional drum onto previously unflocked portions of said article and not on previously flocked portions of said article.
 10. The combination of claim 9 wherein each drum is driven at a peripheral speed equal to the linear speed of said article past said each drum.
 11. The combination of claim 10 wherein each drum is driven at a peripheral speed equal to the linear speed of said article past said drum.
 12. The flocking apparatus of claim 1 wherein said flock distributor permits flock fibers to be discharged from said drum through respective ones of said apertures during the portion of the rotation of said drum when the respective one aperture is closely adjacent said article support and prevents discharge of flock fibers through respective ones of said apertures during other portions of the rotation of said drum. 